Automatic rotary sorter and cylindrical storage system

ABSTRACT

A system for sorting objects having a source for providing the object for sorting and a plurality of receivers, spaced apart horizontally and vertically, for receiving the object after sorting. The system includes object receiving and discharging wings for receiving the object from the source and transferring the object to the receiver. The object receiving and discharging wings move the object horizontally and vertically from the source to a selected receiver. The source and at least one of the receivers are vertically aligned. Also, a system for storing and retrieving objects having storage and retrieval conveyor for providing the object to the system for storage and for retrieving the object from the system after storage, and a plurality of object storage areas spaced apart horizontally and vertically. The system includes object receiving and discharging wings for receiving the object from the storage and retrieval conveyor and transferring the object to the storage area and for receiving the object from the storage area and transferring the object to the storage and retrieval conveyor. The object receiving and discharging wings have move the object horizontally and vertically from the storage and retrieval conveyor to a selected storage area. The object receiving and discharging wings further have move the object horizontally and vertically from the selected object storage area to the storage and retrieval conveyor.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 07/792,211, filed Nov. 13, 1991, and now U.S. Pat.No. 5,284,252, the contents of which are incorporated herein in theirentirety by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to the sorting, storage and retrieval ofobjects, and in particular, to the sorting of objects from a singlesource stream into a plurality of destination streams, and the storageand retrieval of objects between a single storage and retrieval streamand a plurality of storage locations.

2. Statement of Related Art

In the field of package shipping, packages are received from many areasof the country, or even the world, for distribution to a variety ofother areas. Packages arrive at distribution centers in groups sharingcommon sources and leave in groups sharing common destinations. Thus,shipments of common-source packages must be efficiently sorted intoshipments of common-destination packages.

Affixed to each package is a shipping label containing, along with otherinformation, the zip code of the package destination. The zip codes ofthe possible package destinations are organized into twelve differentcategories, with each zip code falling in only one category.

In many known sorting systems, a shipment of packages arrives at adistribution center, usually by truck. The packages are unloaded fromthe truck onto a feed conveyor which transports the packages to a workerwho sorts them. In prior art sorting systems, this sorter reads the zipcode of the destination address of each package as it arrives at the endof the feed conveyor. The sorter determines the appropriate zip codecategory corresponding to the zip code of each package.

Adjacent to the sorter is an array of twelve receiving conveyors,arranged in three different levels of four receiving conveyors each.Each receiving conveyor corresponds to one of the twelve zip codecategories. The sorter must pick up the package from the end of the feedconveyor, turn toward the array of receiving conveyors, and place thepackage onto the correct receiving conveyor.

Each package is then advanced along its appropriate receiving conveyor.A package may then be loaded for further shipment or may continuethrough one or more similar sorting operations before being loaded forfurther shipment. A distribution center may also have multiple shipmentacceptance points. As a result, as many as 20 or 60 sorters may beoperating simultaneously in a distribution center.

There are many problems with these prior art systems. For example,complicated training of employees must be provided to enable them toperform the sorting operations. Furthermore, different sorting stationsmay have different categories of zip codes. Therefore a sorter must knowthe system of categorization of zip codes for an individual sortingstation. As a result, a sorter must be familiar with virtually all theaddresses in the country in order to be able to operate at differentsorting stations.

To operate effectively, a sorter must be able to recognize and selectthe correct receiving conveyor with about 99.9 percent effectiveness.This limits the pool of potential laborers who are able to qualify assorters. Additionally, the package shipping business is growing fasterthan the supply of potential laborers who can perform the physically andmentally demanding tasks of the sorter.

Furthermore, very difficult physical demands are imposed upon a sorter.A typical sorter may sort approximately 1000 packages an hour over anapproximately three and a half hour shift. A typical sorter's physicalcapabilities limit package weight to about 70 pounds and package size toabout 5 feet in any dimension. The number and arrangement of receivingconveyors is also limited by the physical size of the sorters. A typicalsorter is only able to place packages safely and securely on receivingconveyors that are no more than about five feet above ground level.

The timing of the work shifts of the sorters throughout the day furtherreduces the size of the available labor pool. Sorting activity consistsof four shifts distributed roughly evenly through the day and night.Thus, the three-and-a-half hour shifts are separated by roughly two anda half hours, during which sorting activity is not required.

Furthermore, sorters make errors. They may place packages on the wrongreceiving conveyors. They may drop or otherwise damage packages.Additionally, they are subject to injury when sorting packages.

The prior art teaches automatic sorters that are adapted to sortobjects. U.S. Pat. No. 4,867,299, issued to Fukuoka et al. on Sep. 19,1989, teaches a distributor for distributing veneer sheets wherein asingle source stream of veneer sheets is divided into two verticallyarranged destination streams of veneer sheets. This distributor solvessome of the physical limitations inherent in the use of humans in knownpackage sorting systems. For example, the distributor of Fukuoka et al.can work continuously for longer periods of time than a human.Furthermore, it is able to distribute larger and heavier packages than asingle human can handle safely. In addition, such an apparatus has theadvantage of being able to receive one package from the feed conveyor atthe same time that it is depositing another package onto one of thereceiving conveyors.

However, the distributor taught by Fukuoka et al. does not solve all theproblems associated with known package sorting systems. Foremost is thatdistribution by such a distributor is not sorting. For example, packagesorting involves the selective distribution of packages according totheir zip codes. The distribution performed by the distributor taught byFukuoka et al. is simple alternation between the upper and lowerdestination streams. This distributor distributes every other object tothe upper destination stream and the rest of the objects to the lowerdestination stream, without any regard to differences between theobjects distributed. Such a distributor cannot sort packages accordingto their desired destinations in the field of package shipping.

Another problem with the distributor taught by Fukuoka et al. is that itis limited to two destination streams. Known package sorting systemsrequire a sorter to be able to sort a single source stream of packagesinto at least twelve destination streams. Although the distributortaught by Fukuoka et al. could distribute to twelve destination streams,stacking twelve receiving conveyors would require an excessive amount ofvertical space and an excessive amount of travel to place the objects ona selected receiving conveyor. Furthermore, the distributor taught byFukuoka et al. could not distribute packages to the twelve receivingconveyors in known package sorting systems, since those receivingconveyors are arranged in arrays of rows and columns of receivingconveyors.

U.S. Pat. No. 4,326,624, issued to Ewertowski et al. on Apr. 27, 1982,teaches a pallet changer which may be applied to known package sortingsystems. The pallet changer taught by Ewertowski et al. sorts palletsfrom a single source stream of pallets into a plurality of destinationlocations arranged in a circle about the pallet changer. The palletchanger distributes one pallet at a time from the single source streamto a selected destination. The destination is selected according tocharacteristics of the particular pallet being sorted.

However, the pallet changer taught by Ewertowski et al. does not solveall the problems associated with known package sorting systems. Asorting system such as the pallet changer taught by Ewertowski et al.that contained twelve receiving conveyors arranged in a circle about thepallet changer would require an excessive amount of horizontal space.Furthermore, the distributor taught by Ewertowski et al. could notdistribute packages to the known package sorting systems having twelvereceiving conveyors arranged in arrays of rows and columns.

Thus, the prior art does not teach a mechanical sorter capable ofsolving the problems of known package sorting systems which requiredistribution to an array of receiving conveyors.

SUMMARY OF THE INVENTION

In the automatic rotary sorter system of the present invention, packagesare unloaded, for example, from a truck onto a feed conveyor. The feedconveyor advances the packages one by one onto an induction conveyordisposed at the end of the feed conveyor. The induction conveyor is atapered assembly of live lagged rollers. While the feed conveyor mayhold many packages at once, at most one package at a time rests on theinduction conveyor.

The automatic rotary sorter of the present invention is provided with anupright drive shaft to which four horizontal receiving and dischargingwings are slidably coupled. Each receiving and discharging wing is atapered conveyor assembly of reversible live lagged rollers. Reversiblelive rollers are provided on the receiving and discharging wings inorder to permit both on-loading of packages from the induction conveyoronto the receiving and discharging wing and off-loading of packages fromthe receiving and discharging wing onto a selected receiving conveyor.In the present invention, at least one receiving conveyor is positionedsubstantially overhead of the induction conveyor.

In addition to rotational movement, each of the receiving anddischarging wings may move vertically along a respective vertical guiderail on the upright drive shaft. Each receiving and discharging wingtravels vertically independent of the other receiving and dischargingwings. As each receiving and discharging wing rotates past the inductionconveyor, the vertical position of the receiving and discharging wingmay be matched to the vertical position of the induction conveyor. Whena receiving and discharging wing is at the correct position, bothvertically and angularly, relative to the induction conveyor, the liverollers of the induction conveyor and the live rollers of the receivingand discharging wing act cooperatively to transfer the package from theinduction conveyor onto the receiving and discharging wing.

When the trailing edge of the now-laden receiving and discharging wingclears the induction conveyor, the receiving and discharging wing maymove along its vertical guide rail. As the receiving and dischargingwing continues to rotate about the central vertical axis, the level ofthe loaded receiving and discharging wing is matched to the level of theselected receiving conveyor. The receiving conveyor selected may bepositioned substantially overhead of the induction conveyor.

When the receiving and discharging wing is at the correct vertical andangular position relative to the selected receiving conveyor, the liverollers of the receiving and discharging wing and the selected receivingconveyor are activated to transfer the package from the receiving anddischarging wing onto the selected receiving conveyor. The package thenproceeds along the selected receiving conveyor for shipping or furthersorting.

When the trailing edge of the now-unloaded receiving and dischargingwing clears the selected receiving conveyor, the receiving anddischarging wing may again move along its vertical guide rail. As thereceiving and discharging wing continues to rotate about the centralvertical axis, the level of the receiving and discharging wing ismatched to that of the induction conveyor in time to receive anotherpackage.

In the automatic cylindrical storage system of the present invention, anupright drive shaft is provided to which four horizontal receiving anddischarging wings are slidably coupled. Each receiving and dischargingwing is a tapered conveyor assembly of reversible live lagged rollers.In a storage mode, reversible live rollers are provided on the receivingand discharging wings in order to permit both on-loading of packagesfrom a storage and retrieval conveyor onto the receiving and dischargingwing and off-loading of packages from the receiving and discharging wingonto a selected storage rack. In a retrieval mode, reversible liverollers are provided on the receiving and discharging wing in order topermit both off-loading of packages from the receiving and dischargingwing onto the storage and retrieval conveyor and on-loading of packagesfrom a selected storage rack onto the receiving and discharging wing.

In addition to rotational movement, each of the receiving anddischarging wings may move vertically along a respective vertical guiderail on the upright drive shaft. Each receiving and discharging wingtravels vertically independent of the other receiving and dischargingwings. As each receiving and discharging wing rotates past the storageand retrieval conveyor, the vertical position of the receiving anddischarging wing may be matched to the vertical position of the storageand retrieval conveyor. When a receiving and discharging wing is at thecorrect position, both vertically and angularly, relative to the storageand retrieval conveyor, the live rollers of the storage and retrievalconveyor and the live rollers of the receiving and discharging wing actcooperatively to transfer a package from storage and retrieval conveyoronto the receiving and discharging wing or from the receiving anddischarging wing onto the storage and retrieval conveyor.

When the trailing edge of the receiving and discharging wing clears thestorage and retrieval conveyor, the receiving and discharging wing maymove along its vertical guide rail. As the receiving and dischargingwing continues to rotate about the central vertical axis, the level ofthe receiving and discharging wing may be matched to the level of aselected storage rack. When the receiving and discharging wing is at thecorrect vertical and angular position relative to the selected storagerack, the live rollers of the receiving and discharging wing and theselected storage rack may be activated to transfer a package from thereceiving and discharging wing onto the selected storage rack or fromthe selected storage rack onto the receiving and discharging wing.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter which is regarded as theinvention, it is believed that the invention and advantages thereof willbe better understood from the following description taken in connectionwith the accompanying drawings in which:

FIG. 1 is a plan view of the preferred embodiment of the automaticrotary sorter system of the present invention,

FIG. 1A is a top view of an automatic rotary sorter system according toan alternate preferred embodiment of the present invention,

FIG. 1B is a top view of an automatic cylindrical storage systemaccording to an alternate preferred embodiment of the present invention,

FIG. 2 is a side view of the automatic rotary sorter system of FIG. 1,

FIG. 2A is a side view of the automatic rotary sorter system of FIG. 1A,

FIG. 2B is a side view of the automatic cylindrical storage system ofFIG. 1B, and

FIG. 3 is a plan view of an alternative embodiment of the automaticrotary sorter system of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIGS. 1, 2, there are shown, respectively, plan andside views of the preferred embodiment of automatic rotary sorter system4 of the present invention. Automatic rotary sorter system 4 includesobject source conveyor 8, rotating distribution assembly 12, and objectreceiving assembly 16. Rotating distribution assembly 12 of automaticrotary sorter system 4 is provided with upright drive shaft 36 and fourreceiving and discharging wings 40a-d. Object receiving assembly 16 ofautomatic rotary sorter system 4 is provided with a plurality oftransverse conveyors 64. Object source conveyor 8 provides a stream ofsortable objects 20 for sorting by automatic rotary sorter system 4.Sorting within automatic rotary sorter system 4 is achieved through thetransfer of one sortable object 20 at a time from object source conveyor8 to a selected transverse conveyor 64 by receiving and dischargingwings 40a-d of rotating distribution assembly 12. Sortable objects 20are then advanced along selected transverse conveyor 64 for removal fromautomatic rotary sorter system 4.

In the preferred embodiment of automatic rotary sorter system 4,rotating distribution assembly 12, for transferring sortable objects 20from object source conveyor 8 to a selected transverse conveyor 64,consists of rotatably mounted upright drive shaft 36 to which fourreceiving and discharging wings 40a-d are slidably coupled. Eachslidably coupled receiving and discharging wing 40a-d of rotatingdistribution assembly 12 is adapted to: (a) receive sortable objects 20from object source conveyor 8, (b) retain sortable objects 20 duringrotation of rotating distribution assembly 12, and (c) dischargesortable objects 20 onto a selected transverse conveyor 64 of objectreceiving assembly 16.

Upright drive shaft 36 of rotating distribution assembly 12 is alignedalong and rotates about vertical axis of rotation 52. As upright driveshaft 36 rotates about vertical axis of rotation 52, receiving anddischarging wings 40a-d of rotating distribution assembly 12, coupled toupright drive shaft 36, also rotate about vertical axis of rotation 52.In addition to rotating about vertical axis of rotation 52 along withupright drive shaft 36, each receiving and discharging wing 40a-d maymove up and down along upright drive shaft 36 independently of all otherreceiving and discharging wings 40a-d. Additionally, all receiving anddischarging wings 40a-d of rotating distribution assembly 12 may move upand down along upright drive shaft 36 simultaneously.

As each receiving and discharging wing 40a-d of rotating distributionassembly 12 rotates past object source conveyor 8, the vertical positionof receiving and discharging wing 40a-d along upright drive shaft 36 ismatched to the vertical level of object source conveyor 8. Whenreceiving and discharging wing 40a-d of rotating distribution assembly12 passes object source conveyor 8, at most one sortable object 20 istransferred from object source conveyor 8 to receiving and dischargingwing 40a-d.

In the preferred embodiment of automatic rotary sorter system 4, objectreceiving assembly 16 of automatic rotary sorter system 4 includestwelve transverse conveyors 64 spaced apart in three horizontal levels68a-c of four transverse conveyors 64 each. Horizontal levels 68a-c ofobject receiving assembly 16 are disposed vertically one above theother. Thus, each transverse conveyor 64 of object receiving assembly 16is uniquely designated by (i) a vertical level of displacement alongupright drive shaft 36 parallel to vertical axis of rotation 52, and(ii) an angular orientation of upright drive shaft 36 about verticalaxis of rotation 52 relative to, for example, object source conveyor 8.

When sortable object 20 is loaded onto receiving and discharging wing40a-d of rotating distribution assembly 12, the vertical position ofreceiving and discharging wing 40a-d along upright drive shaft 36 ismatched to the vertical level of a selected transverse conveyor 64 ofobject receiving assembly 16 to which sortable object 20 is to betransferred while upright drive shaft 36 is rotating. When receiving anddischarging wing 40a-d of rotating distribution assembly 12 rotates pastselected transverse conveyor 64, sortable object 20 on receiving anddischarging wing 40a-d is transferred from receiving and dischargingwing 40a-d to selected transverse conveyor 64. Once sortable object 20is transferred to selected transverse conveyor 64, the vertical positionof receiving and discharging wing 40a-d along upright drive shaft 36 maythen be matched to the vertical level of object source conveyor 8 forreceiving and sorting of another sortable object 20.

All four receiving and discharging wings 40a-d of rotating distributionassembly 12 may operate simultaneously and independently of each otherwithin automatic rotary sorting system 4. Thus, sortable objects 20 maybe sorted by automatic rotary sorter system 4 at a maximum rate of foursortable objects 20 for each rotation of rotating distribution assembly12. Automatic rotary sorting system 4 of the present invention may sorttwo thousand or more objects an hour.

Automatic rotary sorter system 4 includes object source conveyor 8,rotating distribution assembly 12, and object receiving assembly 16.Rotating distribution assembly 12 of automatic rotary sorter system 4 isprovided with upright drive shaft 36 and at least one receiving anddischarging wing 40a-d. Object receiving assembly 16 of automatic rotarysorter system 4 is provided with a plurality of transverse conveyors 64.Object source conveyor 8 provides a stream of sortable objects 20wherein each sortable object 20 is directed to a selected transverseconveyor 64 within object receiving assembly 16 by rotating distributionassembly 12. Sorting within automatic rotary sorter system 4 is thusachieved through the transfer of one sortable object 20 at a time fromobject source conveyor 8 to selected transverse conveyor 64 by rotatingdistribution assembly 12. Sortable objects 20 are then advanced alongselected transverse conveyor 64 for removal from automatic rotary sortersystem 4.

Object source conveyor 8 of automatic rotary sorter system 4 includesfeed conveyor 24 and induction conveyor 28. Sortable objects 20 areadvanced along feed conveyor 24 toward induction conveyor 28,transferred one at a time onto induction conveyor 28, and thentransferred one at a time onto a receiving and discharging wing 40a-d ofrotating distribution assembly 12. Lagged live rollers 32 of inductionconveyor 28 provide the impetus for moving sortable object 20 alonginduction conveyor 28 and for discharging sortable object 20 ontoreceiving and discharging wings 40a-d.

Induction conveyor 28 is formed to have increasing horizontal width inthe direction toward receiving and discharging wings 40a-d. Thistapering provides increased dwell time during which transfer of sortableobjects 20 from object source conveyor 8 to rotating distributionassembly 12 may occur. The lengths of rollers 32 of induction conveyor28 are therefore selected according to this tapering of inductionconveyor 28. Thus, rollers 32 increase in length in the direction towardreceiving and discharging wings 40a-d.

Rotating distribution assembly 12 of automatic rotary sorter system 4,for transferring sortable objects 20 from object source conveyor 8 to aselected transverse conveyor 64, includes rotatably mounted uprightdrive shaft 36 to which four receiving and discharging wings 40a-d arecoupled. Each receiving and discharging wing 40a-d of rotatingdistribution assembly 12 is adapted to: (a) receive sortable objects 20from object source conveyor 8, (b) retain sortable objects 20 duringrotation of rotating distribution assembly 12, and (c) dischargesortable objects 20 onto object receiving assembly 16. Each receivingand discharging wing 40a-d of rotating distribution assembly 12 isprovided with horizontally aligned, tapered, reversible conveyor 44a-dhaving lagged live rollers 48. The tapering, with an increasing width ofreceiving and discharging wings 40a-d in the radially outward directionfrom upright drive shaft 36, further increases the dwell time fortransfer of sortable objects 20 from object source conveyor 8 toreceiving and discharging wings 40a-d. Lagged live rollers 48 ofreceiving and discharging wings 40a-d are used for receiving sortableobject 20 from induction conveyor 28 of object source conveyor 8 and fordischarging sortable object 20 to transverse conveyors 64 of objectreceiving assembly 16. Corresponding to the tapering of receiving anddischarging wings 40a-d, lagged live rollers 48 increase in length inthe radially outward direction from upright drive shaft 36.

Upright drive shaft 36 is aligned along and rotates about vertical axisof rotation 52. As upright drive shaft 36 rotates about vertical axis ofrotation 52, receiving and discharging wings 40a-d, coupled to uprightdrive shaft 36, also rotate about vertical axis of rotation 52. Thisrotational motion of upright drive shaft 36 and receiving anddischarging wings 40a-d defines a first degree of freedom of motion ofrotating distribution assembly 12.

It will be understood that a structure having linear translation androtation about an axis has two different degrees of freedom. Motion inthe linear degree of freedom provides access to locations in onedimension. These locations are disposed along a line. Similarly, motionin the rotational degree of freedom provides access to locations alongan arc. Motion in these two degrees of freedom, where one degree offreedom is rotational about an axis of rotation and the other degree offreedom is linear and parallel to that axis of rotation, provides accessto locations on the surface of a cylinder.

It will be understood that the rotational motion of upright drive shaft36 and receiving and discharging wings 40a-d of rotating distributionassembly 12 about vertical axis of rotation 52 is motion in therotational degree of freedom. It will also be understood that theindependent and simultaneous motion of receiving and discharging wings40a-d along upright drive shaft 36 is motion in the linear degree offreedom and defines a second degree of freedom of motion of rotatingdistribution assembly 12. Thus, considering both (a) the rotationalmotion of upright drive shaft 36 and receiving and discharging wings40a-d about vertical axis of rotation 52, and (b) the motion ofreceiving and discharging wings 40a-d along upright drive shaft 36,rotating distribution assembly 12 is capable of motion in two degrees offreedom. This two-degree-of-freedom combination of linear and rotationalmotion allows receiving and discharging wings 40a-d to access locationsdistributed cylindrically about vertical axis of rotation 52.

As each receiving and discharging wing 40a-d of rotating distributionassembly 12 rotates past induction conveyor 28 of object source conveyor8, the vertical position of receiving and discharging end 56a-d ofreceiving and discharging wing 40a-d along upright drive shaft 36 ismatched to the vertical level of discharging end 60 of inductionconveyor 28. Discharging end 60 of induction conveyor 28 is shaped toconform with the shape of receiving and discharging ends 56a-d ofrespective receiving and discharging wings 40a-d of rotatingdistribution assembly 12, to transfer sortable objects 20 from inductionconveyor 28 to receiving and discharging wing 40a-d.

In the preferred embodiment of automatic rotary sorter system 4, whenreceiving and discharging wing 40a-d of rotating distribution assembly12 passes induction conveyor 28 of object source conveyor 8, at most onesortable object 20 is transferred from induction conveyor 28 toreceiving and discharging wings 40a-d. This transfer of sortable object20 from induction conveyor 28 to receiving and discharging wing 40a-d ofrotating distribution assembly 12 is accomplished by the action oflagged live rollers 32 of induction conveyor 28 to move sortable object20 from conveyor 28 and lagged live rollers 48 of receiving anddischarging wings 40a-d to move sortable object 20 onto vanes 40a-d.

Each transverse conveyor 64 of object receiving assembly 16 is providedwith its individual acquisition conveyor 72. Each acquisition conveyor72 of transverse conveyors 64 contains lagged live rollers 76. Laggedlive rollers 76 are used for receiving sortable object 20 from receivingand discharging wings 40a-d.

When sortable object 20 is loaded onto receiving and discharging wing40a-d of rotating distribution assembly 12, the vertical position ofreceiving and discharging wing 40a-d along upright drive shaft 36 ismatched to the vertical level of a selected acquisition conveyor 72 oftransverse conveyor 64 to which sortable object 20 is to be transferred.When receiving and discharging wing 40a-d of rotating distributionassembly 12 rotates past receiving end 80a-c of selected acquisitionconveyor 72, sortable object 20 on receiving and discharging wing 40a-dis transferred from receiving and discharging wing 40a-d to selectedacquisition conveyor 72. This transfer may be performed by both liverollers 48 of receiving and discharging wings 40a-d and live rollers 76of acquisition conveyors 72.

Receiving ends 80a-c of acquisition conveyors 72 are shaped to conformwith the shape of receiving and discharging end 56a-d of receiving anddischarging wing 40a-d in order to transfer sortable objects 20 fromreceiving and discharging wing 40a-d to acquisition conveyors 72 oftransverse conveyor 64. This conformity of shape between receiving ends80a-c of acquisition conveyors 72 and receiving and discharging end56a-d of receiving and discharging wing 40a-d increases the dwell timeduring which transfer of sortable objects may occur. In order to achieveconformance of shape, the shapes of receiving ends 80a-c of acquisitionconveyors 72 vary depending upon the orientation of each acquisitionconveyor 72 to the rotational path of receiving and discharging wing40a-d. This conformance of shape is provided by the circular curvatureof receiving ends 80a-c. The lengths of live rollers 76 of acquisitionconveyors 72 vary as the width of acquisition conveyors 72 varies toachieve this conformance of shape. The length of wings 40a-d is adaptedto cause receiving and discharging ends 56a-d to pass substantiallyclose to receiving ends 80a-c in order to permit sortable object 20 topass easily onto acquisition conveyors 72.

As described above, the two degrees of freedom of motion of rotatingdistribution assembly 12 provide access by receiving and dischargingwings 40a-d of rotating distribution assembly 12 to locationsdistributed cylindrically about vertical axis of rotation 52. Thus, theshapes of receiving ends 80a-c of acquisition conveyors 72 of objectreceiving assembly 16 are selected to conform to the cylindricallydefined range of motion of receiving and discharging wings 40a-d.

The transfer of sortable objects 20 from receiving and discharging wings40a-d of rotating distribution assembly 12 to transverse conveyors 64 ofobject receiving assembly 16 is accomplished by the action of liverollers 48 of receiving and discharging wings 40a-d and live rollers 76of acquisition conveyors 72 of transverse conveyors 64. To perform bothloading and unloading of sortable objects 20, live rollers 48 ofconveyor 44a-d of receiving and discharging wings 40a-d are reversible.Once sortable object 20 is transferred to transverse conveyor 64, theimpetus for moving sortable object 20 along transverse conveyors 64 isprovided by lagged live rollers 76 of transverse conveyor 64. Thevertical position of receiving and discharging wing 40a-d along uprightdrive shaft 36 is then matched to the vertical level of inductionconveyor 28 of object source conveyor 8 for receiving and sorting ofanother sortable object 20.

All four receiving and discharging wings 40a-d of rotating distributionassembly 12 may operate simultaneously and independently of each other.For example, assume a sequence of five sortable objects 20a-e (notshown) on source conveyor 8, such that first sortable object 20a is tobe placed on first transverse conveyor 64 of middle level 68b of objectreceiving assembly 16; second sortable object 20b, on last transverseconveyor 64 of top level 68c; third sortable object 20c, on secondtransverse conveyor 64 of top level 68c; fourth sortable object 20d, onlast transverse conveyor 64 of bottom level 68a; and fifth sortableobject 20e, on first transverse conveyor 64 of bottom level 68a.

All five sortable objects 20a-e proceed along feed conveyor 24 towardinduction conveyor 28. First sortable object 20a is transferred fromfeed conveyor 24 to induction conveyor 28. As receiving and dischargingwing 40a rotates past induction conveyor 28 with the vertical positionof receiving and discharging wing 40a along upright drive shaft 36matched to the vertical level of induction conveyor 28, sortable object20a is transferred from induction conveyor 28 onto receiving anddischarging wing 40a. When transfer of sortable object 20a frominduction conveyor 28 onto receiving and discharging wing 40a iscomplete, the vertical position of receiving and discharging wing 40aalong upright drive shaft 36 is matched to the vertical level of middlelevel 68b of object receiving assembly 16.

At the same time that the vertical position of receiving and dischargingwing 40a is adjusted, sortable object 20b is transferred from feedconveyor 24 to induction conveyor 28 and the vertical position ofreceiving and discharging wing 40b is matched to the vertical level ofinduction conveyor 28. As receiving and discharging wing 40b rotatespast induction conveyor 28, sortable object 20b is transferred frominduction conveyor 28 onto receiving and discharging wing 40b. Whentransfer of sortable object 20b from induction conveyor 28 ontoreceiving and discharging wing 40b is complete, the vertical position ofreceiving and discharging wing 40b along upright drive shaft 36 ismatched to the vertical level of top level 68c of object receivingassembly 16.

At the same time that the vertical position of receiving and dischargingwing 40b is adjusted, sortable object 20c is transferred from feedconveyor 24 to induction conveyor 28 and the vertical position ofreceiving and discharging wing 40c is matched to the vertical level ofinduction conveyor 28. As receiving and discharging wing 40c rotatespast induction conveyor 28, sortable object 20c is transferred frominduction conveyor 28 onto receiving and discharging wing 40c.

Meanwhile, as receiving and discharging wing 40a rotates past firsttransverse conveyor 64 of middle level 68b of object receiving assembly16, sortable object 20a is transferred from receiving and dischargingwing 40a onto first transverse conveyor 64 of middle level 68b. Whentransfer of sortable object 20a from receiving and discharging wing 40aonto first transverse conveyor 64 of middle level 68b is complete, thevertical position of receiving and discharging wing 40a is matched tothe vertical level of induction conveyor 28.

When transfer of sortable object 20c from induction conveyor 28 ontoreceiving and discharging wing 40c is complete, the vertical position ofreceiving and discharging wing 40c along upright drive shaft 36 ismatched to the vertical level of top level 68c of object receivingassembly 16. At the same time, sortable object 20d is transferred fromfeed conveyor 24 onto induction conveyor 28 and the vertical position ofreceiving and discharging wing 40d along upright drive shaft 36 ismatched to the vertical level of induction conveyor 28. As receiving anddischarging wing 40d rotates past induction conveyor 28, sortable object20d is transferred from induction conveyor 28 onto receiving anddischarging wing 40d.

Meanwhile, as receiving and discharging wing 40b rotates past lasttransverse conveyor 64 of top level 68c of object receiving assembly 16,sortable object 20b is transferred from receiving and discharging wing40b onto last transverse conveyor 64 of top level 68c. When transfer ofsortable object 20b from receiving and discharging wing 40b onto lasttransverse conveyor 64 of top level 68c is complete, the verticalposition of receiving and discharging wing 40b is matched to thevertical level of induction conveyor 28.

When transfer of sortable object 20d from induction conveyor 28 ontoreceiving and discharging wing 40d is complete, the vertical position ofreceiving and discharging wing 40d along upright drive shaft 36 ismatched to the vertical level of bottom level 68a of object receivingassembly 16. At the same time, sortable object 20e is transferred fromfeed conveyor 24 onto induction conveyor 28 and the vertical position ofreceiving and discharging wing 40a along upright drive shaft 36 ismatched to the vertical level of induction conveyor 28. As receiving anddischarging wing 40a rotates past induction conveyor 28, sortable object20e is transferred from induction conveyor 28 onto receiving anddischarging wing 40a.

Meanwhile, as receiving and discharging wing 40c rotates past secondtransverse conveyor 64 of top level 68c of object receiving assembly 16,sortable object 20c is transferred from receiving and discharging wing40c onto second transverse conveyor 64 of top level 68c. When transferof sortable object 20c from receiving and discharging wing 40c ontosecond transverse conveyor 64 of top level 68c is complete, the verticalposition of receiving and discharging wing 40c is matched to thevertical level of induction conveyor 28.

When transfer of sortable object 20e from induction conveyor 28 ontoreceiving and discharging wing 40a is complete, the vertical position ofreceiving and discharging wing 40a along upright drive shaft 36 ismatched to the vertical level of bottom level 68a of object receivingassembly 16. When receiving and discharging wing 40d rotates past lasttransverse conveyor 64 of bottom level 68a of object receiving assembly16, sortable object 20d is transferred from receiving and dischargingwing 40d onto last transverse conveyor 64 of bottom level 68a. Whentransfer of sortable object 20d from receiving and discharging wing 40donto last transverse conveyor 64 of bottom level 68a is complete, thevertical position of receiving and discharging wing 40d is matched tothe vertical level of induction conveyor 28.

Finally, when receiving and discharging wing 40a rotates past firsttransverse conveyor 64 of bottom level 68a of object receiving assembly16, sortable object 20e is transferred from receiving and dischargingwing 40a onto first transverse conveyor 64 of bottom level 68a. Whentransfer of sortable object 20e from receiving and discharging wing 40aonto first transverse conveyor 64 of bottom level 68a is complete, thevertical position of receiving and discharging wing 40a is matched tothe vertical level of induction conveyor 28, thus completing the sortingof sortable objects 20a-e.

Sortable objects 20 may be sorted by automatic rotary sorter system 4 ata maximum rate of four sortable objects 20 for each rotation of rotatingdistribution assembly 12. If no sortable object 20 is ready for transferfrom induction conveyor 28 to receiving and discharging wing 40a-d asreceiving and discharging wing 40a-d of rotating distribution assembly12 passes induction conveyor 28, then receiving and discharging wing40a-d completes its next rotation without transferring any sortableobject 20 to object receiving assembly 16. In this case, the verticalposition of receiving and discharging wing 40a-d may remain at the levelof induction conveyor 28 as it rotates about vertical axis of rotation52.

In the preferred embodiment, the operations of automatic rotary sortersystem 4 of the present invention are controlled by a programmable logiccontroller (not shown). In exercising that control over automatic rotarysorter system 4, programmable logic controller may perform the followingfunctions. Additionally, the programmable logic controller may performmany other functions.

The programmable logic controller may accept zip code input informationfor each sortable object 20 on object source conveyor 8 and therebydetermine the destination of sortable object 20. Additionally, it mayaccept object length information and object location information foreach sortable object 20 on object source conveyor 8.

Feed conveyor 24 of object source conveyor 8 and live rollers 32 ofinduction conveyor 28 of object source conveyor 8 may be controlled bythe programmable logic controller to transfer sortable objects 20 fromfeed conveyor 24 to induction conveyor 28. Receiving and dischargingwings 40a-d of rotating distribution assembly 12 may be moved alongupright drive shaft 36 of rotating distribution assembly 12 undercontrol of the programmable logic controller. The programmable logiccontroller may also control the rotation of upright drive shaft 36 ofrotating distribution assembly 12 and receiving and discharging wings40a-d of rotating distribution assembly 12 about vertical axis 52.

Live rollers 32 of induction conveyor 28 of object source conveyor 8 andlive rollers 48 of horizontally aligned, tapered, reversible conveyors44a-d of receiving and discharging wings 40a-d of rotating distributionassembly 12 may be controlled by the programmable logic controller totransfer sortable objects 20 from induction conveyor 28 to receiving anddischarging wings 40a-d. The programmable logic controller may selectcorrect transverse conveyor 64 of object receiving assembly 16 for eachsortable object 20. It may also control live rollers 48 of horizontallyaligned, tapered, reversible conveyors 44a-d of receiving anddischarging wings 40a-d of rotating distribution assembly 12 and liverollers 76 of acquisition conveyors 72 of transverse conveyors 64 ofobject receiving assembly 16 to transfer sortable objects 20 fromreceiving and discharging wings 40a-d to selected transverse conveyors64.

In alternative embodiments (not shown) of automatic rotary sorter system4, the impetus for moving sortable objects 20 along object sourceconveyor 8 and transverse conveyors 64 may be provided by conveyorbelts, or any other conventional devices known in the art for suchadvancement. It will be understood by those skilled in the art thatreceiving and discharging wings 40a-d may consist of any suitable devicefor receiving, holding, and transferring sortable objects 20.

In other alternative embodiments or in the embodiment of automaticrotary sorter system 4, rollers 76 of acquisition conveyor 72 oftransverse conveyors 64 of object receiving assembly 16 force sortableobject 20 to one edge of acquisition conveyor 72. To achieve thisforcing of sortable objects 20 to one edge of acquisition conveyor 72,rollers 76 of acquisition conveyor 72 may be arranged at angles withinacquisition conveyor 72 such that one end of each roller 76 is furtheralong acquisition conveyor 72 than the other end of that roller 76.

Although in the preferred embodiment, upright drive shaft 36 is alignedalong and rotates about vertical axis of rotation 52, it will beunderstood to those skilled in the art that such alignment and rotationneed not be relative to vertical axis of rotation 52. Any orientation,including alignment along and rotation about a horizontal axis, iswithin the scope of the present invention.

Furthermore, it will be understood that object receiving assembly 16 mayconsist of more than four transverse conveyors 64 for each horizontallevel 68a-c or fewer than four transverse conveyors 64 for eachhorizontal level 68a-c. Similarly, it will be understood that objectreceiving assembly 16 may consist of more than three horizontal levels68a-c or fewer than three horizontal levels 68a-c.

In addition, it will be understood that the number of transverseconveyors 64 in each horizontal level 68a-c of object receiving assembly16 need not be identical. For example, an alternative embodiment maycontain fifteen transverse conveyors 64 disposed in four horizontallevels 68a-c of four, three, five, and three transverse conveyors 64,respectively.

Referring now to FIGS. 1A, 2A, there are shown, respectively, top andside views of an alternate preferred embodiment of an automatic rotarysorter system 4A of the present invention. Automatic rotary sortersystem 4A includes object source conveyor 8A, rotating distributionassembly 12A, and object receiving assembly 16A. Rotating distributionassembly 12A of automatic rotary sorter system 4A is provided withupright drive shaft 36A and four receiving and discharging wings 40a-d.Object receiving assembly 16A of automatic rotary sorter system 4A isprovided with a plurality of transverse conveyors 64a-d. Object sourceconveyor 8A provides a stream of sortable objects 20 for sorting byautomatic rotary sorter system 4A. Sorting within automatic rotarysorter system 4A is achieved through the transfer of one sortable object20 at a time from object source conveyor 8A to a selected one oftransverse conveyors 64a-d by receiving and discharging wings 40a-d ofrotating distribution assembly 12A. Sortable objects 20 are thenadvanced along selected transverse conveyors 64a-d for removal fromautomatic rotary sorter system 4A. Automatic rotary sorter system 4Adiffers from automatic rotary sorter system 4 in that rotary sortersystem 4A includes a plurality of transverse conveyors 64d positionedsubstantially overhead object source conveyor 8A.

In automatic rotary sorter system 4A, rotating distribution assembly12A, for transferring sortable objects 20 from object source conveyor 8Ato a selected one of transverse conveyors 64a-d, consists of rotatablymounted upright drive shaft 36A to which four receiving and dischargingwings 40a-d are slidably coupled. Each slidably coupled receiving anddischarging wing 40a-d of rotating distribution assembly 12A is adaptedto: (a) receive sortable objects 20 from object source conveyor 8A, (b)retain sortable objects 20 during rotation of rotating distributionassembly 12A, and (c) discharge sortable object 20 onto a selectedtransverse conveyor 64a-d of object receiving assembly 16A.

Upright drive shaft 36A of rotating distribution assembly 12A is alignedalong and rotates about vertical axis of rotation 52A. As upright driveshaft 36A rotates about vertical axis of rotation 52A, receiving anddischarging wings 40a-d of rotating distribution assembly 12A, coupledto upright drive shaft 36A, also rotate about vertical axis of rotation52A. In addition to rotating about vertical axis of rotation 52A alongwith upright drive shaft 36A, each receiving and discharging wing 40a-dmay move up and down along upright drive shaft 36A independently of allother receiving and discharging wings 40a-d. Additionally, all receivingand discharging wings 40a-d of rotating distribution assembly 12A maymove up and down along upright drive shaft 36A simultaneously.

As each receiving and discharging wing 40a-d of rotating distributionassembly 12A rotates past object source conveyor 8A and transverseconveyors 64d, the vertical position of receiving and discharging wing40a-d along upright drive shaft 36A is matched to either the verticallevel of object source conveyor 8A or the vertical level of transverseconveyor 64d. When receiving and discharging wing 40a-d of rotatingdistribution assembly 12A passes object source conveyor 8A, at most onesortable object 20 is transferred from object source conveyor 8A toreceiving an discharging wing 40a-d. Alternatively, when receiving anddischarging wing 40a-d passes object source conveyor 8A, a sortableobject 20 may be transferred from receiving wing 40a-d to a selectedtransverse conveyor 64d positioned substantially overhead sourceconveyor 8A.

In automatic rotary sorter system 4A, object receiving assembly 16A ofautomatic rotary sorter system 4A includes sixteen transverse conveyors64a-d spaced apart in three horizontal levels 68a-c. Horizontal level68a includes the four transverse conveyors 64c; horizontal level 68bincludes the four transverse conveyors 64b; and horizontal level 68cincludes the four transverse conveyors 64c as well as the fourtransverse conveyors 64d positioned substantially overhead conveyor 8A.Thus, each transverse conveyor 64a-d of object receiving assembly 16A isuniquely designated by (i) a vertical level of displacement alongupright drive shaft 36A parallel to vertical axis of rotation 52A, and(ii) an angular orientation of upright drive shaft 36A about verticalaxis of rotation 52A relative to, for example, object source conveyor8A.

When sortable object 20 is off-loaded from receiving and dischargingwing 40a-d of rotating distribution assembly 12A, the vertical positionof receiving and discharging wing 40a-d along upright drive shaft 36A ismatched to the vertical level of a selected transverse conveyor 64a-d ofobject receiving assembly 16A to which sortable object 20 is to betransferred while upright drive shaft 36A is rotating. When receivingand discharging wing 40a-d of rotating distribution assembly 12A rotatespast selected transverse conveyor 64a-d, sortable object 20 on receivingand discharging wing 40a-d is transferred from receiving and dischargingwing 40a-d to selected transverse conveyor 64a-d. Once sortable object20 is transferred to a selected transverse conveyor, the verticalposition of receiving and discharging wing 40a-d along upright driveshaft 36A may then be matched to the vertical level of object sourceconveyor 8A for receiving and sorting of another sortable object 20. Allfour receiving and discharging wings 40a-d of rotating distributionassembly 12A may operate simultaneously and independently of each otherwithin automatic rotary sorting system 4A. Sorting within automaticrotary sorter system 4A is achieved through the transfer of sortableobjects 20 from object source conveyor 8A to a selected transverseconveyor 64a-d by rotating distribution assembly 12A. Sortable objects20 are then advanced along selected transverse conveyor 64a-d forremoval from automatic rotary sorter system 4A.

Object source conveyor 8A of automatic rotary sorter system 4A includesfeed conveyor 24 and induction conveyor 28. Sortable objects 20 areadvanced along feed conveyor 24 toward induction conveyor 28,transferred one at a time onto induction conveyor 28, and thentransferred one at a time onto a receiving and discharging wing 40a-d ofrotating distribution assembly 12. Lagged live rollers 32 of inductionconveyor 28 provide the impetus for moving sortable 20 along inductionconveyor 28 and for discharging sortable object 20 onto receiving anddischarging wings 40a-d. Feed conveyor 24, induction conveyor 28 androllers 32 of sorter system 4A function substantially as described inconnection with sorter system 4 and FIGS. 1, 2 above.

Each receiving and discharging wing 40a-d of rotating distributionassembly 12A is adapted to: (a) receive sortable objects 20 from objectsource conveyor 8A, (b) retain sortable objects 20 during rotation ofrotating distribution assembly 12A, and (c) discharge sortable objects20 onto object receiving assembly 16A. Each receiving and dischargingwing 40a-d of rotating distribution assembly 12A is provided withhorizontally aligned, tapered, reversible conveyor 44a-d having laggedlive rollers 48. Reversible conveyor 44a-d and rollers 48 of sortersystem 4A function substantially as described in connection with sortersystem 4 and FIGS. 1, 2 above.

Upright drive shaft 36A is aligned along and rotates about vertical axisof rotation 52A. As upright drive shaft 36A rotates about vertical axisof rotation 52A, receiving and discharging wings 40a-d, coupled toupright drive shaft 36A, also rotate about vertical axis of rotation52A. This rotational motion of upright drive shaft 36A and receiving anddischarging wings 40a-d defines a first degree of freedom of motion ofrotating distribution assembly 12A. It will also be understood that theindependent and simultaneous motion of receiving and discharging wings40a-d along upright drive shaft 36A is motion in the linear degree offreedom and defines a second degree of freedom of motion of rotatingdistribution assembly 12. This two-degree-of-freedom combination oflinear and rotational motion allows receiving and discharging wings40a-d to access locations distributed cylindrically over a full 360degrees about vertical axis of rotation 52A.

As a receiving and discharging wing 40a-d of rotating distributionassembly 12A rotates past induction conveyor 28 of object sourceconveyor 8A, the vertical position of receiving and discharging end56a-d of receiving and discharging wing 40a-d along upright drive shaft36A may be matched to the vertical level of discharging end 60 ofinduction conveyor 28. Discharging end 60 of induction conveyor 28 isshaped to conform with the shape of receiving and discharging ends 56a-dof respective receiving and discharging wings 40a-d of rotatingdistribution assembly 12, to transfer sortable objects 20 from inductionconveyor 28 to receiving and discharging wing 40a-d. Each transverseconveyor 64a-d of object receiving assembly 16A is provided with itsindividual acquisition conveyor 72. Each acquisition conveyor 72includes a receiving end 80a-d and lagged live rollers 76 which are usedfor receiving sortable object 20 from receiving and discharging wings40a-d. Acquisition conveyors 72 and rollers 76 of sorter system 4Afunction substantially as described in connection with sorter system 4and FIGS. 1, 2 above.

Sortable objects 20 may be sorted by automatic rotary sorter system 4Aat a maximum rate of four sortable objects 20 for each rotation ofrotating distribution assembly 12A. If no sortable object 20 is readyfor transfer from induction conveyor 28 to receiving and dischargingwing 40a-d as receiving and discharging wing 40a-d of rotatingdistribution assembly 12A passes induction conveyor 28, then receivingand discharging wing 40a-d completes its next rotation withouttransferring any sortable object 20 to object receiving assembly 16A. Inthis case, the vertical position of receiving and discharging wing 40a-dmay remain at the level of induction conveyor 28 as it rotates aboutvertical axis of rotation 52A. In addition, if sortable object 20 istransferred from receiving and discharging wing 40a-d to transverseconveyor 64d (positioned substantially overhead induction conveyor 28),then wing 40a-d may complete its next rotation in an empty state beforereceiving a further object 20 from induction conveyor 28.

Referring now to FIGS. 1B, 2B, there are shown, respectively, top andside views of a preferred embodiment of an automatic cylindrical storagesystem 4B of the present invention. Automatic cylindrical storage system4B includes object storage and retrieval conveyor 8B, rotatingdistribution assembly 12B, and object storage assembly 16B. Rotatingdistribution assembly 12B is provided with upright drive shaft 36B andfour receiving and discharging wings 40a-d. Object receiving assembly16B is provided with a plurality of object storage racks 65a-d. Objectstorage and retrieval conveyor 8B is adapted to provide a stream ofsortable objects 20 to automatic cylindrical storage system 4B forstorage. Object storage and retrieval conveyor 8B is reversible and,when not providing objects 20 to system 4B, may be adapted to retrieveobjects 20 from cylindrical storage system 4B. Storage withincylindrical storage system 4B is achieved through the transfer of asortable object 20 from object storage and retrieval conveyor 8B to aselected object storage rack 65a-d by receiving and discharging wings40a-d of rotating distribution assembly 12B. Retrieval from cylindricalstorage system 4B is achieved through the transfer of a sortable object20 from a storage rack 65a-d to object storage and retrieval conveyor 8Bby receiving and discharging wings 40a-d.

In the preferred embodiment of automatic cylindrical storage system 4B,rotating distribution assembly 12B, for transferring sortable objects 20from object storage and retrieval conveyor 8B to a selected storage rack65a-d and from a selected storage rack 65a-d to object storage andretrieval conveyor 8B, consists of rotatably mounted upright drive shaft36B to which four receiving and discharging wings 40a-d are slidablycoupled. Each slidably coupled receiving and discharging wing 40a-d ofrotating distribution assembly 12B is adapted to: (a) receive sortableobjects 20 from object storage and retrieval conveyor 8B, (b) retainsortable objects 20 during rotation of rotating distribution assembly12B, (c) discharge sortable objects 20 onto a selected storage rack65a-d of object storage assembly 16B, (d) receive sortable objects 20from a selected storage rack 65a-d, and (e) discharge sortable objects20 retrieved from storage racks 65a-d onto storage and retrievalconveyor 8B.

Upright drive shaft 36B of rotating distribution assembly 12B is alignedalong and rotates about vertical axis of rotation 52B. As upright driveshaft 36B rotates about vertical axis of rotation 52B, receiving anddischarging wings 40a-d of rotating distribution assembly 12B, coupledto upright drive shaft 36B, also rotate about vertical axis of rotation52B. In addition to rotating about vertical axis of rotation 52B alongwith upright drive shaft 36B, each receiving and discharging wing 40a-dmay move up and down along upright drive shaft 36B independently of allother receiving and discharging wings 40a-d. Additionally, all receivingand discharging wings 40a-d of rotating distribution assembly 12B maymove up and down along upright drive shaft 36B simultaneously.

When cylindrical storage system 4B is operating in its storage mode suchthat object storage and retrieval conveyor 8B has been activated in aforward direction to carry sortable objects 20 for storage tocylindrical storage system 4B, the vertical position of each receivingand discharging wing 40a-d along upright drive shaft 36B may be matchedto the vertical level of either object storage and retrieval conveyor 8Bor storage rack 65d as receiving and discharging wing 40a-d rotates pastobject storage and retrieval conveyor 8B. In this storage mode, whenreceiving and discharging wing 40a-d of rotating distribution assembly12B rotates past object storage and retrieval conveyor 8B, a sortableobject 20 may be transferred from object storage and retrieval conveyor8B to receiving and discharging wing 40a-d provided the vertical levelof receiving and discharging wing 40a-d has been matched to the verticallevel of storage and retrieval conveyor 8B. Alternatively, when storagesystem 4B is operating in its storage mode, a sortable object 20 may betransferred from receiving and discharging wing 40a-d to a selectedstorage rack 65d positioned substantially overhead object conveyor 8B asreceiving and discharging wing 40a-d passes object conveyor 8B providedthe vertical level of receiving and discharging wing 40a-d has been,matched to the vertical level of storage rack 65d.

Similarly, when storage system 4B is operating in its retrieval mode,such that object storage and retrieval conveyor 8B has been activated ina reverse direction to carry sortable objects 20 from cylindricalstorage system 4B, the vertical position of each receiving anddischarging wing 40a-d may be matched to the vertical level of eitherobject storage and retrieval conveyor 8B or storage rack 65d as eachreceiving and discharging wing 40a-d rotates past object conveyor 8B. Inthis retrieval mode, when receiving and discharging wing 40a-d ofassembly 12B passes object storage and retrieval conveyor 8B, a sortableobject 20 may be transferred from receiving and discharging wing 40a-dto object storage and retrieval conveyor 8B provided the vertical levelof receiving and discharging wing 40a-d has been matched to the verticallevel of storage and retrieval conveyor 8B. Alternatively, when storagesystem 4B is operating in its retrieval mode, a sortable object 20 maybe transferred from a selected storage rack 65d positioned substantiallyoverhead object storage and retrieval conveyor 8B to receiving anddischarging wing 40a- d as receiving and discharging wing 40a-d passesobject conveyor 8B provided the vertical level of receiving anddischarging wing 40a-d has been matched to the vertical level of storagerack 65d.

In the preferred embodiment of automatic cylindrical storage system 4B,object receiving assembly 16B includes sixteen object storage racks65a-d spaced apart in three horizontal levels 68a-c. Horizontal level68a includes the four storage racks 65c; horizontal level 68b includesthe four storage racks 65b; and horizontal level 68c includes the fourstorage racks 65a as well as the four storage racks 65d positionedsubstantially overhead object conveyor 8B. Thus, each object storagerack 65a-d is uniquely designated by (i) a vertical level ofdisplacement along upright drive shaft 36B parallel to vertical axis ofrotation 52B, and (ii) an angular orientation of upright drive shaft 36Babout vertical axis of rotation 52B relative to, for example, objectstorage and retrieval conveyor 8B.

When sortable object 20 is off-loaded from receiving and dischargingwing 40a-d of rotating distribution assembly 12B in the storage mode ofsystem 4B, the vertical position of receiving and discharging wing 40a-dalong upright drive shaft 36B is matched to the vertical level of aselected storage rack 65a-d to which sortable object 20 is to betransferred for storage while upright drive shaft 36B is rotating. Inthe storage mode, when receiving and discharging wing 40a-d of rotatingdistribution assembly 12B rotates past selected storage rack 65a-d,sortable object 20 on receiving and discharging wing 40a-d istransferred from receiving and discharging wing 40a-d to selectedstorage rack 65a-d. In the storage mode, once sortable object 20 istransferred to selected storage rack 65a-d, the vertical position ofreceiving and discharging wing 40a-d along upright drive shaft 36B maythen be matched to the vertical level of object storage and retrievalconveyor 8B for receiving another sortable object 20 for storage.

When sortable object 20 is on-loaded onto receiving and discharging wing40a-d in the retrieval mode of system 4B, the vertical position ofreceiving and discharging wing 40a-d along upright shaft 36B is matchedto the vertical level of a selected storage rack 65a-d from whichsortable object 20 is to be retrieved while upright drive shaft 36B isrotating. In the retrieval mode, when receiving and discharging wing40a-d of assembly 12B rotates past selected storage rack 65a-d, sortableobject 20 in selected storage rack 65a-d is transferred from selectedstorage rack 65a-d to receiving and discharging wing 40a-d. In theretrieval mode, once sortable object 20 is transferred from storage rack65a-d to receiving and discharging wing 40a-d, the vertical position ofreceiving and discharging wing 40a-d along upright drive shaft 36b maythen be matched to the vertical level of object storage and retrievalconveyor 8B for discharging retrieved object 20 onto storage andretrieval conveyor 8B.

All four receiving and discharging wings 40a-d of rotating distributionassembly 12B may operate simultaneously and independently of each otherwithin automatic cylindrical storage system 4B. Storage within automaticcylindrical storage system 4B is thus achieved through the transfer ofsortable objects 20 from object storage and retrieval conveyor 8B toselected storage rack 65a-d by rotating distribution assembly 12B.Retrieval within automatic cylindrical storage system 4B is similarlyachieved through the transfer of sortable objects 20 from selectedstorage rack 65a-d to object storage and retrieval conveyor 8B byrotating distribution assembly 12B. Lagged live rollers 32 of objectstorage and retrieval conveyor 8B provide the impetus for moving object20 along storage and retrieval conveyor 8B and for discharging andreceiving sortable object 20 onto and from receiving and dischargingwings 40a-d.

Each receiving and discharging wing 40a-d of rotating distributionassembly 12B is adapted to: (a) receive sortable objects 20 from objectstorage and retrieval conveyor 8B or selected storage rack 65a-d, (b)retain sortable objects 20 during rotation of rotating distributionassembly 12B, and (c) discharge sortable objects 20 onto selectedstorage rack 65a-d or object storage and retrieval conveyor 8B. Eachreceiving and discharging wing 40a-d of rotating distribution assembly12B is provided with horizontally aligned, tapered, reversible conveyor44a-d having lagged live rollers 48. Reversible conveyor and rollers 48of system 4B function substantially as described in connection withsorter system 4 and FIGS. 1, 2 above.

Upright drive shaft 36B is aligned along and rotates about vertical axisof rotation 52B. As upright drive shaft 36B rotates about vertical axisof rotation 52B, receiving and discharging wings 40a-d, coupled toupright drive shaft 36B, also rotate about vertical axis of rotation52B. This rotational motion of upright drive shaft 36B and receiving anddischarging wings 40a-d defines a first degree of freedom of motion ofrotating distribution assembly 12B. It will also be understood that theindependent and simultaneous motion of receiving and discharging wings40a-d along upright drive shaft 36B is motion in the linear degree offreedom and defines a second degree of freedom of motion of rotatingdistribution assembly 12B. This two-degree-of-freedom combination oflinear and rotational motion allows receiving and discharging wings40a-d of assembly 12B to access locations distributed cylindrically overa full 360 degrees about vertical axis of rotation 52B.

As a receiving and discharging wing 40a-d of rotating distributionassembly 12B rotates past object storage and retrieval conveyor 8B, thevertical position of receiving and discharging end 56a-d of receivingand discharging wing 40a-d along upright drive shaft 36B may be matchedto the vertical level of discharging end 60 of object storage andretrieval conveyor 8B. Discharging end 60 of object storage andretrieval conveyor 8B is shaped to conform with the shape of receivingand discharging ends 56a-d of respective receiving and discharging wings40a-d of rotating distribution assembly 12B, to transfer sortableobjects 20 from object storage and retrieval conveyor 8B to receivingand discharging wing 40a-d and from receiving and discharging wing 40a-dto object storage and retrieval conveyor 8B.

Each storage rack 65a-d of assembly 16B is provided with its individualstorage conveyor 72. Each storage conveyor 72 includes a receiving end80a-d and lagged live rollers 76. Lagged live rollers 76 are used forreceiving object 20 from and discharging sortable object 20 ontoreceiving and discharging wings 40a-d.

It will be understood that assembly 16B may consist of more than four(or more than eight) storage racks 65 for each horizontal level 68a-c orfewer than four storage racks 65 for each horizontal level 68a-c.Similarly, it will be understood that assembly 16B may consist of morethan three horizontal levels 68a-c of storage racks 65. Furthermore, itwill be understood that the number of storage racks 65 in eachhorizontal level 68a-c of assembly 16B need not be identical.

Referring now to FIG. 3, there is shown a plan view of automatic rotarysorter system 5. Automatic rotary sorter system 5 is an alternativeembodiment of automatic rotary sorter system 4 of the present invention.Rotary distribution assembly 12 of automatic sorter system 5 is providedwith upright drive shaft 36 and three receiving and discharging wings40a-c. The use of three receiving and discharging wings 40a-c instead offour provides for increased dwell time and the ability to sort largerobjects. It will also be understood by those skilled in the art thatrotating distribution assembly 12 may consist of more than fourreceiving and discharging wings 40a-d or fewer than three receiving anddischarging wings 40a-d.

It will further be understood that various changes in the details,materials, and arrangements of the parts which have been described andillustrated in order to explain the nature of this invention may be madeby those skilled in the art without departing from the principle andscope of the invention as expressed in the following claims.

I claim:
 1. A system for sorting a plurality of objects having objectsource means for providing said objects for sorting and a plurality ofobject receiving means for receiving said objects after sorting, whereinthe individual object receiving means of said plurality of objectreceiving means are spaced apart both horizontally and vertically,comprising:a plurality of object receiving and discharging means forreceiving said objects from said object source means and transferringsaid objects to said object receiving means; and, each of said objectreceiving and discharging means having means for moving an object ofsaid plurality of objects both horizontally and vertically from thevicinity of said object source means to the vicinity of a selected oneof said horizontally and vertically spaced apart object receiving meansto transfer said object to said selected object receiving means; whereinsaid object source means and at least one of said object receiving meansare vertically aligned, each of said object receiving and dischargingmeans is coupled to a rotatable member which rotates about an axis ofrotation, and said rotatable member rotates about said axis of rotationcontinuously.
 2. The system in accordance with claim 1, wherein saidobject source means comprises object transferring means for transferringsaid object from said object source means to said object receiving anddischarging means.
 3. The system in accordance with claim 2, whereinsaid object transferring means comprises an induction conveyor.
 4. Thesystem in accordance with claim 3, wherein said induction conveyorcomprises a live roller.
 5. The system in accordance with claim 4,wherein said live roller is lagged.
 6. The system in accordance withclaim 4, wherein said induction conveyor has a forward direction andsaid live roller is aligned at an angle with respect to said forwarddirection to urge said object toward a side of said induction conveyor.7. The system in accordance with claim 4, wherein said inductionconveyor is tapered.
 8. The system in accordance with claim 3, whereinsaid induction conveyor is tapered.
 9. The system in accordance withclaim 8, wherein each object receiving and discharging means of saidplurality of object receiving and discharging means is adapted to movealong said rotatable member in positive and negative directionssubstantially parallel to said axis of rotation.
 10. The system inaccordance with claim 9, wherein each object receiving and dischargingmeans of said plurality of object receiving and discharging means movesalong said rotatable member in positive and negative directionsindependently of each remaining object receiving and discharging meansof said plurality of object receiving and discharging means.
 11. Thesystem in accordance with claim 9, wherein each object receiving anddischarging means of said plurality of object receiving and dischargingmeans moves along said rotatable member in positive and negativedirections simultaneously with each remaining object receiving anddischarging means of said plurality of object receiving and dischargingmeans.
 12. The system in accordance with claim 1, wherein said objectsource means comprises:a feed conveyor for providing said object forsorting; and, an induction conveyor for receiving said object from saidfeed conveyor and providing said object to said object receiving anddischarging means.
 13. The system in accordance with claim 1, whereinthe shape of said object source means conforms with the shape of saidobject receiving and discharging means.
 14. The system in accordancewith claim 1, wherein said rotatable member rotates about said axis ofrotation at a constant rate.
 15. The system in accordance with claim 1,wherein said axis of rotation is aligned substantially vertically. 16.The system in accordance with claim 1, wherein said object receiving anddischarging means is tapered.
 17. The system in accordance with claim 1,wherein said object receiving and discharging means comprises a conveyorassembly.
 18. The system in accordance with claim 17, wherein saidconveyor assembly is reversible.
 19. The system in accordance with claim17, wherein said conveyor assembly comprises a live roller.
 20. Thesystem in accordance with claim 19, wherein said live roller is lagged.21. The system in accordance with claim 19, wherein said conveyorassembly has a forward direction and said live roller is aligned at anangle with respect to said forward direction to urge said object towarda side of said conveyor assembly.
 22. The system in accordance withclaim 17, wherein said conveyor assembly is tapered.
 23. The system inaccordance with claim 1, wherein four of said object receiving anddischarging means are provided.
 24. The system in accordance with claim1, wherein the shape of each of said object receiving and dischargingmeans conforms to the shape of said horizontally and vertically spacedapart object receiving means.
 25. The system in accordance with claim 1,wherein each of said horizontally and vertically spaced apart objectreceiving means comprises means for receiving said object from saidobject receiving and discharging means.
 26. The system in accordancewith claim 25, wherein each of said means for receiving said object fromsaid object receiving and discharging means is a transverse conveyor.27. The system in accordance with claim 26, wherein said receiving meanscomprises a live roller.
 28. The system in accordance with claim 27,wherein said live roller is lagged.
 29. The system in accordance withclaim 27, wherein said receiving means is tapered.
 30. The system inaccordance with claim 1, comprising sixteen of said horizontally andvertically spaced apart object receiving means arranged in three spacedapart substantially horizontal rows, each of said horizontal rows havingat least four of said horizontally spaced apart object receiving means.31. A method for sorting an object of a plurality of objects in a systemhaving object source means for providing said object for sorting and aplurality of object receiving means for receiving said object aftersorting, wherein the object receiving means of said plurality of objectreceiving means are spaced apart both horizontally and vertically,comprising the steps of:(a) providing said object for sorting by saidobject source means; (b) transferring said object from said objectsource means to object distribution means; (c) simultaneously movingsaid object horizontally and vertically by said object distributionmeans from said object source means to a selected one of said pluralityof object receiving means; and, (d) transferring said object from saidobject distribution means to said selected object receiving means;wherein said object source means and at least one of said objectreceiving means are vertically aligned, wherein:said movement of saidobject by said object distribution means comprises rotating movementapplied to said object by rotation of said object distribution meansabout an axis of rotation; and said rotation of said object distributionmeans about said axis of rotation is continuous.
 32. The method inaccordance with claim 31, wherein said rotation of said objectdistribution means about said axis of rotation is at a constant rate.33. The method in accordance with claim 31, wherein said verticalmovement of said object by said object distribution means comprisesmotion of said object distribution means in the positive and negativevertical directions.
 34. The method in accordance with claim 31, whereinsaid horizontal and vertical movement of said object by said objectdistribution means comprises both horizontal rotation of said objectdistribution means about an axis of rotation and vertical motion of saidobject distribution means substantially parallel to said axis ofrotation.
 35. The method in accordance with claim 34, wherein saidobject distribution means comprises a plurality of receiving anddischarging means having means for moving vertically along said axis ofrotation independently of each other substantially parallel to said axisof rotation.
 36. The method in accordance with claim 35, wherein saidvertical movements of individual receiving and discharging means of saidplurality of receiving and discharging means occur simultaneously witheach other.
 37. The method in accordance with claim 34, wherein saidobjects are sorted at a maximum rate in accordance with a predeterminednumber of receiving and discharging means forming said objectdistribution means.
 38. A system for sorting an object of a plurality ofobjects having object source means for providing said object for sortingand a plurality of object receiving means for receiving said objectafter sorting, wherein the individual object receiving means of saidplurality of object receiving means are spaced apart both horizontallyand vertically, comprising:object receiving and discharging means forreceiving said object from said object source means and transferringsaid object to said object receiving means; and said object receivingand discharging means having means for moving said object bothhorizontally and vertically from the vicinity of said object sourcemeans to the vicinity of a selected one of said horizontally andvertically spaced apart object receiving means to transfer said objectto said selected object receiving means, whereina first end of saidobject receiving and discharging means is coupled to a rotatable memberwhich rotates continuously about an axis of rotation; said objectreceiving and discharging means is tapered wherein said first end ofsaid object receiving and discharging means is narrower than a secondend of said object receiving and discharging means; and said second endof said object receiving and discharging means is alternately positionedadjacent to said object source means and said object receiving meansduring said continuous rotation of said rotatable member.
 39. The systemin accordance with claim 38, wherein the shape of said object sourcemeans conforms with the shape of said object receiving and dischargingmeans.
 40. The system in accordance with claim 38, comprising aplurality of said object receiving and discharging means, wherein eachof said object receiving and discharging means is coupled to saidrotatable member.
 41. The system in accordance with claim 38, whereinsaid rotatable member rotates about said axis of rotation at a constantrate.
 42. The system in accordance with claim 38, wherein the shape ofsaid object receiving and discharging means conforms to the shape ofsaid horizontally and vertically spaced apart object receiving means.43. A method for sorting an object of a plurality of objects in a systemhaving object source means for providing said object for sorting and aplurality of object receiving means for receiving said object aftersorting, wherein the object receiving means of said plurality of objectreceiving means are spaced apart both horizontally and vertically,comprising the steps of:(a) providing said object for sorting by saidobject source means; (b) transferring said object from said objectsource means to object distribution means; (c) horizontally andvertically moving said object by said object distribution means fromsaid object source means to a selected one of said plurality of objectreceiving means; and, (d) transferring said object from said objectdistribution means to said selected object receiving means; wherein saidobject source means and at least one of said object receiving means arevertically aligned, whereinsaid movement of said object by said objectdistribution means comprises rotating movement applied to said object byrotation of said object distribution means about an axis of rotation,and said rotation of said object distribution means about said axis ofrotation is continuous.
 44. The method in accordance with claim 43,wherein said rotation of said object distribution means about said axisof rotation is at a constant rate.
 45. The method in accordance withclaim 43, wherein said object distribution means comprises a pluralityof receiving and discharging means having means for moving verticallyalong said axis of rotation independently of each other substantiallyparallel to said axis of rotation.
 46. The method in accordance withclaim 45, wherein said vertical movements of individual receiving anddischarging means of said plurality of receiving and discharging meansoccur simultaneously with each other.
 47. A system for storing andretrieving an object of a plurality of objects having object storage andretrieval conveyor means for providing said object to said system forstorage and for retrieving said object from said system after storage,and a plurality of object storage means for receiving said object forstorage and discharging said object after storage, wherein theindividual object storage means of said plurality of object storagemeans are spaced apart both horizontally and vertically,comprising:object receiving and discharging means for receiving saidobject from said object storage and retrieval conveyor means andtransferring said object to said object storage means and for receivingsaid object from said object storage means and transferring said objectto said object storage and retrieval conveyor means; and said objectreceiving and discharging means having means for moving said object bothhorizontally and vertically from the vicinity of said object storage andretrieval conveyor means to the vicinity of a selected one of saidhorizontally and vertically spaced apart object storage means totransfer .said object from said object storage and retrieval conveyormeans to said selected object storage means for storage; and said objectreceiving and discharging means having means for moving said object bothhorizontally and vertically from the vicinity of said selected objectstorage means to the vicinity of said object storage and retrievalconveyor means to transfer said object from said selected object storagemeans to said object storage and retrieval conveyor means for retrieval,whereina first end of said object receiving and discharging means iscoupled to a rotatable member which rotates continuously about an axisof rotation; said object receiving and discharging means is taperedwherein said first end of said object receiving and discharging means isnarrower than a second end of said object receiving and dischargingmeans; and said second end of said object receiving and dischargingmeans is alternately positioned adjacent to said object storage andretrieval conveyor means and said object storage means during saidcontinuous rotation of said rotatable member.
 48. The system inaccordance with claim 47, wherein the shape of said object storage andretrieval conveyor means conforms with the shape of said objectreceiving and discharging means.
 49. The system in accordance with claim47, comprising a plurality of said object receiving and dischargingmeans, wherein each of said object receiving and discharging means iscoupled to said rotatable member.
 50. The system in accordance withclaim 49, wherein each object receiving and discharging means of saidplurality of object receiving and discharging means is adapted to movealong said rotatable member in positive and negative directionssubstantially parallel to said axis of rotation and independently ofeach remaining object receiving and discharging means of said pluralityof object receiving and discharging means.
 51. The system in accordancewith claim 47, wherein the shape of said object receiving anddischarging means conforms to the shape of said horizontally andvertically spaced apart object storage means.
 52. A method for storingand retrieving an object of a plurality of objects in a system havingobject conveyor means for providing said object to said system forstorage and object conveyor means for retrieving said object from saidsystem after storage, and a plurality of object storage means forreceiving said object for storage and discharging said object afterstorage, wherein the object storage means of said plurality of objectstorage means are spaced apart both horizontally and vertically,comprising the steps of:(a) providing said object for storage by saidobject conveyor means for providing said object; (b) transferring saidobject from said object conveyor means for providing said object toobject distribution means; (c) horizontally and vertically moving saidobject by said object distribution means from said object conveyor meansfor providing said object to a selected one of said plurality of objectstorage means; (d) transferring said object from said objectdistribution means to said selected object storage means; (e)transferring said object from said selected object storage means to saidobject distribution means; (f) horizontally and vertically moving saidobject by said object distribution means from said selected objectstorage means to said object conveyor means for retrieving said object;and (g) transferring said object from said object distribution means tosaid object conveyor means for retrieving said object, whereinsaidmovement of said object by said object distribution means comprisesrotating movement applied to said object by rotation of said objectdistribution means about an axis of rotation, and said rotation of saidobject distribution means about said axis of rotation is continuous. 53.The method in accordance with claim 52, wherein said object distributionmeans comprises a plurality of receiving and discharging means havingmeans for moving vertically along said axis of rotation independently ofeach other substantially parallel to said axis of rotation.
 54. Themethod in accordance with claim 53, wherein said vertical movements ofindividual receiving and discharging means of said plurality of saidreceiving and discharging means occur simultaneously with each other.